Blank for making containers and a resulting container having a decorated end panel

ABSTRACT

The present invention is directed toward a polygonal container and a blank for making the polygonal container. The ends of the polygonal container are provided with a plurality of pie-shaped triangular sections that can provide unique decorative experience to the user of a consumer product contained and dispensed from therein.

FIELD OF THE INVENTION

This invention relates to making three-dimensional structures by foldingflat sheet materials to form an article useful for decoration or, on alarger scale, an article used as a general purpose support structure. Aspecific provides both a package and container for forming a decorativepolygonal container.

BACKGROUND OF THE INVENTION

A variety of containers that are presently in use are formed from one ormore paperboard blanks that are divided by fold lines into a pluralityof panels. This type of container has attained great popularity becauseit is inexpensive to produce and takes little storage space before it isfolded and formed into a container suitable for containing articles ofmanufacture. In addition, it can be made attractive and providesadequate protection for many types of articles that may be disposedtherein.

Most containers of this type include a top formed by a singlerectangular top panel that is joined to a side panel along a fold line.If it is desired to have a more elaborate top or bottom portion, eitherfor added structural protection or for aesthetic reasons, it has usuallybeen necessary to depart from folded container construction, thussacrificing any inherent advantages.

SUMMARY OF THE INVENTION

A first embodiment of the present disclosure provides for a blank offoldable material. The blank comprises a flat, substantiallyrectangular, blank of foldable material having top, bottom, left andright side edges, and a plurality of interconnected body panels disposedbetween the left and right side edges. Each of the panels extends fromthe top edge and the bottom edge. The top edge and the bottom edge havea plurality of peaks and valleys. A first portion of the plurality ofpeaks and valleys are joined by curvilinear lines and a second portionof the peaks and valleys are joined by straight lines. The curvilinearlines joining the peaks and valleys of the top portion are adjacent atleast one of the straight lines joining the peaks and valleys of the topportion. The blank also comprises a first plurality of fold linesadjacent both the top edge and the bottom edge. The first plurality offold lines comprises a plurality of identical arch-shaped lines and aplurality of straight vertical lines. The arch-shaped fold lines arearranged side by side with the sides meeting and terminating at pointson the valleys of both the top and bottom edges. The straight verticalfold lines connect the apexes of the arched shapes and the peaks alongthe top and bottom edges between the sides of the arches. The blank alsocomprises a second plurality of arch-shaped fold lines disposed betweenand connecting the apexes of the arched shapes. Each of the arch-shapedfold lines separates each of the panels into a first body region and asecond region containing the plurality of fold lines adjacent both thetop edge and the bottom edge. The right and left side edges are joinableto first form a cylinder having a circumference defined by a pluralityof the first body regions. The top edge is folded inward along the foldlines and the bottom edge is folded inward along the fold lines to forma substantially flat panel at the top and a substantially flat panel atthe bottom.

A second embodiment of the present disclosure provides for a polygonalcontainer. The container comprises a flat, substantially rectangular,blank of foldable material having top, bottom, left and right sideedges, and a plurality of interconnected body panels disposed betweenthe left and right side edges. Each of the panels extends from the topedge and the bottom edge. The top edge and the bottom edge have aplurality of peaks and valleys. A first portion of the plurality ofpeaks and valleys are joined by curvilinear lines and a second portionof the peaks and valleys are joined by straight lines. The curvilinearlines joining the peaks and valleys of the top portion are adjacent atleast one of the straight lines joining the peaks and valleys of the topportion. The blank also comprises a first plurality of fold linesadjacent both the top edge and the bottom edge. The first plurality offold lines comprises a plurality of identical arch-shaped lines and aplurality of straight vertical lines. The arch-shaped fold lines arearranged side by side with the sides meeting and terminating at pointson the valleys of both the top and bottom edges. The straight verticalfold lines connect the apexes of the arched shapes and the peaks alongthe top and bottom edges between the sides of the arches. The blank alsocomprises a second plurality of arch-shaped fold lines disposed betweenand connecting the apexes of the arched shapes. Each of the arch-shapedfold lines separates each of the panels into a first body region and asecond region containing the plurality of fold lines adjacent both thetop edge and the bottom edge. The right and left side edges are joinableto first form a cylinder having a circumference defined by a pluralityof the first body regions. The top edge is folded inward along the foldlines and the bottom edge is folded inward along the fold lines to forma substantially flat panel at the top and a substantially flat panel atthe bottom. Sealing means is disposed within a region of each flat panelcircumscribed and formed by the top and bottom edges respectively.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of an exemplary blank for a paper package;

FIG. 2 is a perspective view of an exemplary container formed from theblank similar to that shown in FIG. 1; and,

FIG. 3 is a plan view of the top of the exemplary container of FIG. 2.

DESCRIPTION OF THE PREFERRED EMBODIMENT

The term machine direction (MD) is known to those of skill in the art asthe direction of travel of a web material through any processingequipment. The cross-machine direction (CD) is orthogonal and coplanarto the MD. The Z-direction is orthogonal to both the machine andcross-machine directions.

FIG. 1 shows an unfolded carton blank 10 of one embodiment of thepresent invention. The body portion and the end walls forming a properand complete container may be assembled from a single carton blank 10.The carton blank 10 is preferably formed from a paperboard materialwhich has been suitably cut and scored as shown. It should be understoodthat a container having at least three side walls can be formed inaccordance with the present disclosure. However, one of skill in the artwould readily appreciate that a container having at least five sidewalls can be formed in a similar manner in accordance with the presentdisclosure.

As shown, the unfolded carton blank 10 is provided with a plurality ofparallel extending score lines d defining a plurality of body panelportions. As shown, each of the plurality of parallel extending scorelines d are parallel to the CD. However, the plurality of parallelextending score lines d can be oriented in any direction necessary toform each of the body panel portions shown. In the exemplary embodimentshown, carton blank 10 is provided with five parallel extending scorelines d. Each body panel is bounded by an adjacent pair of the parallelextending score lines d. Thus, a first pair of parallel extending scorelines d form first body panel 14. A second pair of parallel extendingscore lines d form second body panel 16. Likewise a third 18, fourth 20,a and fifth body panel 22 are formed by succeeding adjacent parallelextending score lines d with fifth body panel 22 having left side edge eforming the outer edge of the panel. However, one of skill in the artwill realize that any number of parallel extending score lines d can beprovided so as to obtain a resulting container having a cross-section ofany desired arcuate or polygonal contour. The parallel extending scorelines d are preferably disposed generally parallel to the CD. In theembodiment shown, each of the body panels 14, 16, 18, 20, 22 aredisposed collectively elongate in the MD.

Disposed adjacent to each body panel 14, 16, 18, 20, 22 of carton blank10 are a pair of side panels. In the embodiment shown, a first sidepanel of a particular body panel is disposed at a first end of the bodypanel on the longitudinal axis (e.g., in the embodiment shown along theCD) of the body panel. A second side panel is disposed on thelongitudinal axis of the body panel and distal from the first sidepanel. Each side panel could be defined as an extension of therespective body panel and defining the CD edge of the respective bodypanel.

In other words, each side panel is bounded by extensions of the parallelextending score lines d, the top and bottom MD edges forming theboundaries of carton blank 10, and arcuate score lines a, a′ that aredisposed generally parallel to the MD and extend archingly across eachbody panel forming carton blank 10. By way of non limiting example,first side panel 26 and sixth side panel 38 are disposed upon distal CDends of first body panel 14. Naturally, second side panel 28 and seventhside panel 40 are disposed upon distal ends of second body panel 16,third side panel 30 and eighth side panel 42 are disposed upon distalends of third body panel 18, fourth side panel 32 and ninth side panel44 are disposed upon distal ends of fourth body panel 20, and fifth sidepanel 34 and tenth side panel 46 are disposed upon distal ends of fifthbody panel 22. Each side panel is bounded and separated from thecorresponding body panel by an arcuate score line a, a′.

It was surprisingly found that each arcuate score line a, a′ facilitatesa Z-direction rotation (i.e., a rotation out of the MD/CD plane of thecarton blank 10) of each side panel 26, 28, 30, 32, 34/38, 40, 42, 44,46 about an axis formed by the arcuate score line a, a′ from thecorresponding body panel 14, 16, 18, 20, 22. As can be seen in FIG. 2,rotation provides the two ends of the resulting container 54 formed byadjacent side panels 26, 28, 30, 32, 34/38, 40, 42, 44, 46 to foldnearly flat (i.e. substantially planar or even planar). Having two endsof the resulting container 54 formed by adjacent side panels 26, 28, 30,32, 34/38, 40, 42, 44, 46 that can fold essentially flat facilitates thepackaging of multiple resulting containers 54 as well as facilitatingthe ability to provide adjacent resulting containers 54 in aclosest-packing orientation that maximizes the number of resultingcontainers 54 in a given amount of shelf space.

Returning again to FIG. 1, top and bottom edges of the carton blank 10include outwardly rounded edges (or segments) with quasi-alternatinglinear edges (or segments). Left side edge e and right side edge f arevertical and straight and parallel with the CD. Edge f is interrupted byshapes that form three closure tabs: first closure tab f1, secondclosure tab f2, and third closure tab f3. When forming the resultingcontainer 54, first closure tab f1, second closure tab f2, and thirdclosure tab f3 can be adhered to body panel 22 proximate to edge e byany means known to those of skill in the art. When first closure tab f1,second closure tab f2, and third closure tab f3 are adhered to bodypanel 22, it was found suitable to provide an additional score line gthat facilitates folding of the edge-adhered carton blank 10 into aflattened condition for shipping due to the odd number of body panelsused to form resulting container 54.

A plurality of arch-shaped fold lines (b/c and b′/c′) are arranged alongboth edges with the arch-shaped fold lines along the bottom (b′/c′) ofcarton blank 10 being symmetrical with the arch-shaped fold linesdisposed along the top (b/c) of carton blank 10. Preferably, thearch-shaped fold lines along the bottom (b′/c′) of carton blank 10 arealigned with the arch-shaped fold lines along the top (b/c) of cartonblank 10. The arches are arranged side-by-side and the arch-shaped foldlines (b/c and b′/c′) which represent the sides of the arches terminatealong each edge at a valley disposed between adjacent arches formed bythe outwardly rounded edges and quasi-alternating linear edges. Eacharch shaped fold line (b/c and b′/c′) terminates at a vertex formed bythe intersection of the extensions of the parallel extending score linesd and arcuate score lines a, a′. All dotted lines which represent theextensions of the parallel extending score lines d in FIG. 1 are creasedin order to aid in the folding of carton blank 10 and the formation ofresulting container 54, so that the extensions of the parallel extendingscore lines d are encouraged to fold in the opposite direction from thearch-shaped fold lines (b/c and b′/c′).

The extensions of the parallel extending score lines d may be describedmore specifically regarding the arch shapes that appear along the topand bottom edges of the carton blank 10 shown in FIG. 1. Extensions ofthe parallel extending score lines d are each disposed between an apexof an arch shape forming the top and bottom edges of carton blank 10 andthe intersection formed by arch shaped fold lines (b/c and b′/c′) ofadjacent body panels and adjacent arcuate score lines a, a′ disposedupon adjacent body panels. While other fold lines may be pre-creased,the extensions of the parallel extending score lines d are preferablyperforated to provide an inward bias to the folding of each recessformed by adjacent arcuate score lines a, a′ and adjacent arch shapedfold lines b/c, b′/c′. Further clarity will be given to the inventionwith regard to the arch shapes of carton blank 10 infra.

As shown in FIG. 2 and FIG. 3, the folded resulting container 54 isshown with body panels and side panels disposed in their intended finalconfiguration. As can be seen, one side panel is rotated about anarcuate score line a that separates each side panel 26, 28, 30, 32, 34from the corresponding body panel 14, 16, 18, 20, 22. Concurrently withsuch rotation, each side panel 26, 28, 30, 32, 34 is folded aboutcorresponding arch-shaped fold lines b, c and forms an apex betweenadjacent side panels 26, 28, 30, 32, 34 consistent with the extensionsof the parallel extending score lines d that separates adjacent bodypanels 14, 16, 18, 20, 22. As shown, the resulting folds produce an endof resulting container 54 that resembles a plurality of pie-shapedtriangular sections that are bounded by arch-shaped fold lines b, c,arcuate score line a, and a portion of the top edge of carton blank 10.Naturally, the bottom portion of carton blank 10 can form an end similarto that described supra to resemble a plurality of pie-shaped triangularsections that are bounded by arch-shaped fold lines b′, c′, arcuatescore line a′, and a portion of the bottom edge of carton blank 10.

The finally resulting container 54 can then be closed and held in aclosed manner with sealing means 56. The sealing means 56 may compriseany sealing means known to those of skill in the art for retainingrelevant portions of the finally formed resulting container 54 in fixedrelation to each other. By way of non-limiting example, sealing means 56may comprise glue disposed at the intersection of all folded sidepanels, a tape strip disposed upon the surface forming the side ofresulting container 54 and contacting each side panel forming the end ofresulting container 54, a locking tab that engages at least two portionsof the sides forming resulting container 54, and the like. Similarly,tabs can be included upon portions of the top and bottom edges formingcarton blank 10. These tabs can then be resultingly disposed in aface-to-face relationship upon the folding described supra that resultsin the formation of an end of resulting container 54. Depositing anadhesive or other substance upon opposed portions of the tabs can thenfixably position each pie-shaped portion of the end of resultingcontainer 54.

As shown in FIGS. 1 and 2, a preferred embodiment of the carton blank 10forms a resulting container 54 suitable for storing articles therein.Exemplary, but non-liming, articles include consumer products. Suchconsumer products can be edible or non-edible. Edible consumer productscan include candy, snack products, such as snack chips, pretzels, andthe like. Non-edible products can include, but are not limited to,tissue products, facial tissues, paper toweling, bath tissue, hardware,combinations thereof, and the like. In order to facilitate removal ofproducts disposed within resulting container 54, access panel 50 may bedisposed upon at least one body panel of the carton blank 10. The accesspanel 50 may be formed by perforations in order to facilitate itsremoval from the finally formed resulting container 54. One or morefinger grip region 52 may be formed in concert with access panel 50 inorder to facilitate gripping of the access panel 50 and removal ofaccess panel 50 from resulting container 54.

A plurality of resulting containers 54 can be co-packaged or co-wrappedwith other resulting containers 54 to provide for a package containingseveral resulting containers. This has been found to provide aconvenient means for a consumer to obtain several resulting containers54 containing similar products therein without the inconvenience ofhaving to handle several individual resulting containers 54. Such aco-packaging or co-wrapping execution can use a polymeric film or othersuitable bundling means any machinery known to those of skill in the artto bulk wrap several resulting container 54 together.

It should also be realized by one of skill in the art that the resultingcontainer 54 can be creatively decorated with indicium or indicia thatcoordinate the outer surface of the resulting container defined by bodypanels 14, 16, 18, 20, 22 with the pie-shaped triangular sectionsforming the ends of resulting container 54 and being substantiallybounded by two of the plurality of straight vertical lines d, d′ and oneof the second plurality of arch-shaped fold lines a, a′. By way ofnon-limiting example the container portion defined by body panels 14,16, 18, 20, 22 could be provided as a representative fruit, cookie,berry, nut, and the like. Accordingly, the pie-shaped triangularsections forming the ends of resulting container 54 could becoordinatingly decorated to represent a portion, or slice, of a piecontaining the fruit, cookie, berry, or nut, or can represent across-sectional view of the fruit, cookie, berry, or nut. Clearly, thereare an innumerable number of suitable coordinated designs for use withthe instantly disclosed container. For example, if the resultingcontainer 54 is envisioned to hold candy therein, body panels 14, 16,18, 20, 22 could be decorated with a design representing a perspectiveview of a jar containing the candy. The pie-shaped triangular sectionsforming the ends of resulting container 54 could be designed torepresent a cross-sectional view of such a container.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact dimensions and values recited.Instead, unless otherwise specified, each such dimension and/or value isintended to mean both the recited dimension and/or value and afunctionally equivalent range surrounding that dimension and/or value.For example, a dimension disclosed as “40 mm” is intended to mean “about40 mm”.

All documents cited in the Detailed Description of the Invention are, inrelevant part, incorporated herein by reference; the citation of anydocument is not to be construed as an admission that it is prior artwith respect to the present invention. To the extent that any meaning ordefinition of a term in this written document conflicts with any meaningor definition of the term in a document incorporated by reference, themeaning or definition assigned to the term in this written documentshall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

1. A blank of foldable material, said blank comprising: a flat,substantially rectangular, blank of foldable material having top,bottom, left and right side edges, and a plurality of interconnectedbody panels disposed between said left and right side edges, each ofsaid panels extending from said top edge and said bottom edge; said topedge and said bottom edge having a plurality of peaks and valleys, afirst portion of said plurality of peaks and valleys being joined bycurvilinear lines and a second portion of said peaks and valleys beingjoined by straight lines, said curvilinear lines joining said peaks andvalleys of said top portion being adjacent at least one of said straightlines joining said peaks and valleys of said top portion; a firstplurality of fold lines adjacent both said top edge and said bottomedge, comprising a plurality of identical arch-shaped lines and aplurality of straight vertical lines, said arch-shaped fold linesarranged side by side with the sides meeting and terminating at pointson the valleys of both said top and bottom edges, said straight verticalfold lines connecting the apexes of said arched shapes and the peaksalong said top and bottom edges between the sides of the arches; asecond plurality of arch-shaped fold lines disposed between andconnecting said apexes of said arched shapes, each of said arch-shapedfold lines separating each of said panels into a first body region and asecond region containing said plurality of fold lines adjacent both saidtop edge and said bottom edge; whereby joining the right and left sideedges to first form a cylinder having a circumference defined by aplurality of said first body regions and then folding the top edgeinward along said fold lines and folding the bottom edge inward alongsaid fold lines forms a substantially flat panel at the top and asubstantially flat panel at the bottom, each of said substantially flatpanels having integrally-formed support ribs which abut end to end. 2.The blank of claim 1 wherein said plurality of straight vertical linesfurther comprise a series of perforations that separate adjacent distalends of each of said plurality of inter-connected body panels.
 3. Theblank of claim 1 wherein said plurality of interconnected body panelsfurther comprises five body panels.
 4. The blank of claim 3 furthercomprising an additional score line disposed in one of said plurality ofinterconnected body panels.
 5. The blank of claim 1 wherein said firstplurality of fold lines and said second plurality of fold lines arepre-creased and said plurality of straight vertical lines are perforatedto facilitate folding.
 6. The blank of claim 1 wherein said blank isformed from a paperboard material.
 7. The blank of claim 1 wherein saidblank is foldable into a finally folded container.
 8. The blank of claim7 wherein said finally folded container is suitable for containing aconsumer product.
 9. The blank of claim 8 wherein said consumer productis selected from the group consisting of tissue products, facialtissues, paper toweling, bath tissue, and combinations thereof.
 10. Apolygonal container comprising: a flat, substantially rectangular, blankof foldable material having top, bottom, left and right side edges, anda plurality of interconnected body panels disposed between said left andright side edges, each of said panels extending from said top edge andsaid bottom edge; said top edge and said bottom edge having a pluralityof peaks and valleys, a first portion of said plurality of peaks andvalleys being joined by curvilinear lines and a second portion of saidpeaks and valleys being joined by straight lines, said curvilinear linesjoining said peaks and valleys of said top portion being adjacent atleast one of said straight lines joining said peaks and valleys of saidtop portion; a first plurality of fold lines adjacent both said top edgeand said bottom edge, said first plurality of fold lines comprising aplurality of identical arch-shaped lines and a plurality of straightvertical lines, said arch-shaped fold lines arranged side by side withthe sides meeting and terminating at points on the valleys of both saidtop and bottom edges, said straight vertical fold lines connecting theapexes of said arched shapes and the peaks along said top and bottomedges between the sides of the arches; a second plurality of arch-shapedfold lines disposed between and connecting said apexes of said archedshapes, each of said arch-shaped fold lines separating each of saidpanels into a first body region and a second region containing saidplurality of fold lines adjacent both said top edge and said bottomedge; whereby joining the right and left side edges to first form acylinder having a circumference defined by a plurality of said firstbody regions and then folding the top edge inward along said fold linesand folding the bottom edge inward along said fold lines forms asubstantially flat panel at the top and a substantially flat panel atthe bottom; and, sealing means disposed within a region of each flatpanel circumscribed and formed by said top and bottom edgesrespectively.
 11. The polygonal container of claim 10 wherein saidplurality of straight vertical lines further comprise a series ofperforations that separate adjacent distal ends of each of saidplurality of inter-connected body panels.
 12. The polygonal container ofclaim 10 wherein said plurality of interconnected body panels furthercomprises five body panels.
 13. The polygonal container of claim 12further comprising an additional score line disposed in one of saidplurality of interconnected body panels.
 14. The polygonal container ofclaim 10 wherein said first plurality of fold lines and said secondplurality of fold lines are pre-creased and said plurality of straightvertical lines are perforated to facilitate folding.
 15. The polygonalcontainer of claim 10 wherein said blank is formed from a paperboardmaterial.
 16. The polygonal container of claim 10 wherein said blank isfoldable into a finally folded container.
 17. The polygonal container ofclaim 16 wherein said finally folded container is suitable forcontaining a consumer product.
 18. The polygonal container of claim 17wherein said consumer product is selected from the group consisting oftissue products, facial tissues, paper toweling, bath tissue, andcombinations thereof.
 19. The polygonal container of claim 10 whereinsaid sealing means further comprises at least two tabs disposed on andadjacent said top edge, said tabs being engageable in a face-to-facerelationship when said top edge is folded inward along said fold linesforming said substantially flat panel.
 20. The polygonal container ofclaim 10 wherein said substantially flat panel comprises a plurality ofpie-shaped triangular sections, each of said pie-shaped triangularsections being substantially bounded by two of said plurality ofstraight vertical lines and one of said second plurality of arch-shapedfold lines.